Chemical mechanical polishing for forming a shallow trench isolation structure

ABSTRACT

A method of chemical-mechanical polishing for forming a shallow trench isolation is disclosed. A substrate having a number of active regions, including a number of relative large active regions and a number of relative small active regions, is provided. The method comprises the following steps. A silicon nitride layer on the substrate is first formed A number of shallow trenches are formed between the active regions An oxide layer is formed over the substrate, so that the shallow trenches are filled with the oxide layer. A partial reverse active mask is formed on the oxide layer. The partial rever active mask has an opening at a central part of each relative large active region. The opening exposes a portion of the oxide layer. The opening has at least a dummy pattern. The oxide layer on the central part of each large active region is removed to expose the silicon nitride layer. The partial reverse active mask is removed The oxide layer is planarized to expose the silicon nitride layer.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent application Ser. No. 09/991,395, filed Nov. 20, 2001 now U.S. Pat. No. 6,486,040 which is a continuation of U.S. patent application Ser. No. 09/692,251, filed Oct. 19, 2000 now U.S. Pat. No. 6,448,159 which is a divisional of U.S. patent application Ser. No. 09/111,007, filed Jul. 7,1998, now U.S. Pat. No. 6,169,012 B1, which claims priority from Taiwan Application No. 87108699, filed Jun. 3, 1998, all the disclosures of which are herein specifically incorporated by this reference.

This application claims the priority benefit of Taiwan application serial no 87108699, filed Jun. 3, 1998, the full disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a chemical mechanical polishing (CMP) applied in forming shallow trench isolation (STI), and more particularly, to a processes of forming a STI structure combining CMP, using a partial reverse active mask.

2. Description of Related Art

CMP is now a technique ideal for applying in global planarization in very large scale integration (VLSI) and even in ultra large scale integration (ULSI). Moreover, CMP is likely to be the only reliable technique as the feature size of the integrated circuit (IC) is highly reduced. Therefore, it is of great interest to develope and improve the CMP technique in order to cut down the cost.

As the IC devices are continuously sized down to a linewith of 0.25 μm or even 0.18 μm (deep sub-half micron), using CMP to planarize the wafer surface, especially to planarize the oxide layer on the surface of the shallow trench, becomes even more important. To prevent the dishing effect occuring at the surface of a larger trench during CMP process and to obtain a superior CMP uniformity, a reverse tone active mask was proposed, cooperated with an etching back process.

Typically, the activel regions have varied sizes and the shallow trenches between the active regions also have different sizes FIG. 1A to FIG. 1E are cross sectional views showing the process steps for forming shallow trench isolation, using CMP Referring to FIG. 1A, on a substrate 10, a pad oxide 15 and a silicon nitride layer 16 are deposited successively. By photolithography, the substrate 10, the pad oxide layer 15 and the silicon nitride layer 16 are anisotropically etched to form shallow trenches 14 a, 14 b, 14 c and define active regions 12 a, 12 b, 12 c, 12 d. The sizes of the shallow trenches 14 a, 14 b, 14 c are different since the sizes of the active regions 12 a, 12 b, 12 c, 12 d are varied.

Next, referring to FIG. 1B, an oxide layer 18 is deposited by atmosphere pressure chemical vapor deposition (APCVD) on a substrate 10 to fill the interior of the shallow trenches 14 a, 14 b, 14 c. However, due to the step coverage of the oxide layer 18, the deposited oxide layer 18 has an uneven surface and a rounded shaped. Then, a photoresist layer is coated on the surface of the oxide layer 16 and patterned to form a reverse active mask 20 by photolithography. The reverse active mask 20 covers the shallow trenches 14 a, 14 b, 14 c and is complementary to the active regions 12 a, 12 b, 12 c, 12 d However, during the formation of the reverse active mask, misalignment causes the oxide layer 18 to cover more than the shallow trenches 14 a, 14 b,14 c.

Referring to FIG. 1C, the oxide layer 18 exposed outside the reverse active mask 20 is etched until the silicon nitride layer 16 is exposed so that only a part of the silicon oxide layer 18, the silicon oxide layer 18 a, is formed. After removing the reverse active mask 20, as shown in FIG. 1D, it is observable that the silicon oxide layer 18 a remained does not fully cover the shallow trenches 14 a, 14 b, 14 c at one sides of the shallow trenches 14 a, 14 b, 14 c, therefore, forming cavities 22, but at the other sides over-cover the shallow trenches 14 a, 14 b, 14 c, forming photo-overlape 24

Referring to FIG. 1E, the portion of the oxide layer 18 a higher than the shallow trenches 14 a, 14 b, 14 c is polished by CMP until the surface of the silicon nitride layer 16 is exposed. Therefore, the silicon nitride layer 16 and the silicon oxide layer 18 a are at the same level. The profile of the silicon oxide layer 18 a formed by APCVD is rather rounded and the APCVD silicon oxide layer 18 a is hard to be planarized. Moreover, it is obvious that the silicon oxide layer 18 a does not fully fill the shallow trenches 18 a, 18 b, 18 c but form the concaves 22. The undesired concaves 22 may cause kink effect and consequent short circuit or leakage current which therefore influence the yield.

As a result, it is important to overcome the problems coming after the formation of the concaves due to the misalignment of the reverse active mask during the process of CMP, especially, while nowadays the linewidth is decreasing.

SUMMARY OF THE INVENTION

It is therefore an objective of the present invention to provide a method of chemical-mechanical polishing for forming a shallow trench isolation. A substrate having a number of active regions, including a number of relative large active regions and a number of relative small active regions, is provided. The method comprises the following steps. A silicon nitride layer on the substrate is first formed. A number of shallow trenches are formed between the active regions. An oxide layer is formed over the substrate, so that the shallow trenches are filled with the oxide layer. A partial reverse active mask is formed on the oxide layer. The partial rever active mask has an opening at a central part of each relative large active region The opening exposes a portion of the oxide layer. The opening has at least a dummy pattern. The oxide layer on the central part of each large active region is removed to expose the silicon nitride layer The partial reverse active mask is removed The oxide layer is planarized to expose the silicon nitride layer.

BRIEF DESCRIPTION OF DRAWINGS

The invention can be more fully understood by reading the following detailed description of the preferred embodiments, with reference made to the accompanying drawings, wherein:

FIG. 1A to FIG. 1E are cross-sectional views showing the process steps of forming a conventional shallow trench using a reverse active mask;

FIG. 2A to FIG. 2E are cross-sectional views showing the process steps of forming shallow trenches using a partial reverse active mask according to a preferred embodiment of the invention, and

FIG. 3A to FIG. 3D illustrate the partial reverse active mask according to a preferred embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The invention provides a process for forming STI, combining the partial reverse active mask and CMP, using high density plasma chemical vapor deposition (HDCVD). This process prevents the formation of concaves in the shallow trenches due to the misalignment of the reverse active mask, which consequently causes short circuit or leakage current.

Referring to FIG. 2A, active regions 42 a, 42 b are defined on a substrate 40 first by depositing a pad oxide layer 45 and a silicon nitride layer 46, and then by photolithography and trench etching to form shallow trenched 44 between the active regions 42 a, 42 b The sizes of the shallow trenshes are varied since the sizes of the active regions 42 a, 42 b are different. Then, a silicon oxide layer 48 is deposited over the substrate 40 and filling the trenches 44, preferred by high density plasma chemical vapor deposition (HDPCVD) The profile of the silicon oxide layer 48 on the active region 42 a, 42 b is at a higher level than that of the silicon oxide layer 48 on the shallow trenches 44 since the shallow trenches is fallen in the substrate 40. The HDPCVD oxide layer 48 on the active region 42 a,42 b has a sharp profile, as shown in FIG. 2B, which is different from the conventional.

Referring to FIG. 2C, a photoresist layer is coated on the oxide layer 48 and defined to form a partial reverse active mask 50 by photolithography. The partial reverse active mask 50 has an opening 52 at the central part of the larger active region 42 a. Since the opening 50 exposes only the central part of the silicon oxide layer 48 at the larger active region 42 a, the silicon oxide layer 46 over the shallow trenches 44 will not be exposed even though misalignment occurs.

Referring to FIG. 2D, using the reverse active mask 50 as a mask, the exposed silicon oxide layer 48 at the larger active region 42 a is etched back until the silicon nitride layer 46 is exposed. The reverse active mask is then peeled. Then, only the oxide layer 48 b on the smaller active region 42 b and a small portion of the silicon oxide layer 48 a through etching back on the larger active region 42 a are remained. The remained silicon oxide layer 48 a and 48 b formed preferrably by HDPCVD have sharp profile and is therefore easy to be planarized by CMP. Also, the sizes of the remained silicon oxide layer 48 a and 48 b are more or less similar so that the consistence of CMP is increased.

Next, referring to FIG. 2E, the remained silicon oxide layer 48 a and 48 b (as shown in FIG. 2D) are polished by CMP, using the silicon nitride layer 46 as an etching stop layer so that the silicon oxide layer 48 c in the shallow trenches and the silicon nitride layer 46 are almost at the same level.

In the above embodiment, a partial reverse active mask is employed for forming a shallow trench isolation In FIG. 3A to FIG. 3D, a method of forming a partial reverse active mask is shown. As shown in FIG. 3A, to define a photo-mask pattern, active regions are formed first. The active regions include a larger active region pattern 60 and a smaller active region pattern 62.

Referring to FIG. 3B, the larger active region pattern 60 and the smaller active pattern region 62 are shrunk as shown in the figure. The shrinking larger active region pattern and the shrinking smaller active region pattern are denoted as 60 a and 62 a respectively.

Referring to FIG. 3C, the shrinking process is continued until the shrinking smaller active region pattern 62 a disappears. The shrinking distance is about 0.5 μm to 2 μm each side so that active region patterns with maximum radius of less than 1˜4 μm will disappear. Next, the shrinking larger active region 60 a is enlarged until the profile of it is a little bit smaller than the profile of the original larger active region pattern. The profile of the larger active region pattern at the stage is denoted as 60 b. The shrinking large active region pattern 62 a is enlarged with a dimension of about 0.2 μm to 2 μm each side. This enlarged dimension is smaller than the shrinking distance mentioned above.

Referring to FIG. 3D, the partial reverse active mask 60 b is located at the central part of the larger active region 60 but slightly smaller than the larger active region. One characteristic of the present invention is that the partial reverse active mask pattern 60 b at the larger active region 60 has dummy pattern 64 so that dishing effect at the larger active region 60 can be avoided. By applying this photo-mask pattern in forming a shallow trench isolation, the central part of an active region is exposed, whereas the edge part of the active region is covered by a photo-resist. A partial reverse active mask pattern is thus obtained.

The advantages of the invention are:

(1) The oxide layer formed by HDCVD has a pyramid-like profile, so that using chemical-mechanical polishing, the oxide layer is planarized easily.

(2) Using a partial reverse active mask to etch away the oxide layer on the central part of an active region, only the oxide layer on the edge part of the active region and on a small active region is remained. The profile of the remaining oxide layer is pyramid-like and has a better uniformity Therefore, a recess formed while polishing a large trench is avoided.

(3) The dishing effect on the large active region is avoided since the partial reverse active mask has a dummy pattern.

(4) Since only the oxide layer on the central part of an active region is etched away by using a partial reverse active mask, even when a misalignment occurs, the oxide layer within the trench is not etched. The kink effect is prevented. As a consequence, the current leakage and the short circuit caused by kink effect are avoided, so that the yield of wafer is enhanced.

Other embodiment of the invention will appear to those skilled in the art from consideration of the specification and practice of the invention disclosed herein It is intended that the specification and examples to be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims. 

1. A method of chemical-mechanical polishing for forming a shallow trench isolation, wherein a substrate having a plurality of active regions, including a plurality of relatively large active regions and a plurality of relatively small active regions, is provided, the method comprising the steps of: forming a plurality of shallow trenches between the active regions; forming an oxide layer over the substrate, so that the shallow trenches are filled therewith; forming a partial reverse active mask on the oxide layer, wherein the partial reverse active mask has an opening at each relatively large active region, wherein the opening exposes a portion of the oxide layer, and wherein the openings in the oxide lever comprise a dummy pattern that includes at least one protrusion portion; removing portions of the oxide layer on each large active region; removing the partial reverse active mask; and planarizing the oxide layer.
 2. The method of claim 1, further comprising forming an alignment mark in the substrate, wherein the alignment mark comprises another shallow trench in the substrate.
 3. The method of claim 2, wherein the shallow trench is formed by photolithography and etching.
 4. The method of claim 1, wherein the oxide layer is formed by high density plasma chemical vapor deposition.
 5. The method of claim 1, wherein the portions of the oxide layer are removed by anisotropic etching.
 6. The method of claim 1, further comprising forming a silicon nitride layer on the substrate before said forming of the oxide layer.
 7. The method of claim 6, wherein the portions of the oxide layer exposed by the opening in the partial reverse active mask are removed using the silicon nitride layer as an etching stop layer.
 8. The method of claim 1, wherein the oxide layer is planarized by chemical mechanical polishing.
 9. A method of forming a semiconductor device, comprising: depositing a pad oxide layer and a silicon nitride layer on at least portions of a substrate; forming a plurality of shallow trenches in the substrate, wherein the shallow trenches define boundaries of active regions of the semiconductor device; depositing a silicon oxide layer over at least portions of the silicon nitride layer, wherein the silicon oxide layer fills the shallow trenches; coating a photoresist layer on at least portions of the silicon oxide layer to form a partial reverse active mask; etching said at least portions of the silicon oxide layer exposed by the partial reverse active mask, wherein the etched said at least portions of the silicon oxide layer includes a dummy pattern that comprises similarly sized protrusion portions over at least one of the active regions; removing at least portions of the partial reverse active mask; and planarizing said at least portions of the silicon oxide layer.
 10. The method of claim 9, wherein the shallow trenches are formed by photolithography and trench etching.
 11. The method of claim 9, wherein the size of the active regions of the semiconductor device varies.
 12. The method of claim 9, wherein the size of the shallow trenches varies.
 13. The method of claim 9, wherein depositing the silicon oxide layer is performed by HDPCVD.
 14. The method of claim 9, wherein coating the photoresist layer on at least portions of the silicon oxide layer to form the partial reverse active mask comprises performing a photolithography step.
 15. The method claim 9, wherein coating the photoresist layer on at least portions of the silicon oxide layer to form the partial reverse active mask comprises forming an opening at the central part of a larger active region.
 16. The method of claim 9, wherein etching at least portions of the silicon oxide layer exposed by the partial reverse active mask comprises etching until portions of the silicon nitride layer are exposed.
 17. The method of claim 9, wherein planarizing at least portions of the silicon oxide layer comprises a CMP process.
 18. The method of claim 17, wherein the silicon nitride layer acts as an etching stop.
 19. The method of claim 1, wherein the dummy pattern comprises similar sized remaining portions of the oxide layer within the relatively large active region.
 20. The method of claim 19, wherein the oxide layer is formed by a high density plasma chemical vapor deposition (HDPCVD) process.
 21. The method of claim 19, wherein the dummy pattern is adapted to increase a consistency and uniformity of a chemical mechanical polishing (CMP) process during the planarizing of the oxide layer.
 22. The method of claim 1, comprising the step of forming the partial reverse active mask used for the dummy pattern in part by shrinking the plurality of relatively large active regions and the plurality of relatively small active regions by a first amount until the plurality of relatively small active regions disappear.
 23. The method of claim 22, comprising the step of forming the partial reverse active mask used for the dummy pattern in part by enlarging the plurality of relatively large active regions by a second amount less than the first amount, so that the partial reverse active mask is smaller than the plurality of relatively 